User-definable electrical test query for vehicle quality assurance testing during manufacture

ABSTRACT

A method establishes test setpoints for vehicle electrical testing during vehicle manufacture. The method includes implementing test setpoints for a test protocol using software in a system computer, such that the setpoints can be changed by an operator of the system computer. A portable tester adjacent the vehicle generates a query to the system computer, and in response, the setpoints are transferred to the tester. Then, a test protocol is executed by the portable tester to generate test results in accordance with the test setpoints.

FIELD OF THE INVENTION

The present invention relates generally to vehicle test systems, andmore particularly to systems and methods for testing electrical systemsof vehicles during manufacturing.

BACKGROUND OF THE INVENTION

During vehicle manufacturing, it is necessary to conduct various testsof the newly made vehicles to ensure that the vehicles operatesatisfactorily. Among the quality assurance tests conducted duringvehicle manufacturing is testing of the vehicle's electrical system,after it has been installed in the vehicle.

In existing vehicle assembly plants, electrical testing is conducted atan electrical test segment of the assembly line that is dedicated solelyto the electrical testing. As vehicles are transported on the assemblyline through the electrical testing segment, large, monument-likeelectrical test consoles are moved along with the vehicles on a trolleythat is parallel to the assembly line. Each console is connected to acable, and the cable terminates in a plug that a test technician canengage with a test socket underneath a vehicle's dashboard. Once aconsole has been connected to a vehicle via the cable, the consoleexecutes a series of tests of the vehicle's electrical system as thetrolley moves the console along the assembly line with the vehicle.

While effective for its intended purpose, the above-described systemrequires a portion of the assembly line be dedicated to electricaltesting. This consumes space in the assembly plant that could otherwisebe used for other purposes. Also, the above-described system requireslarge test consoles and accompanying trolleys to move the consoles,which is expensive. Further, the cables that connect the consoles to thevehicles can cause interference with nearby equipment and people.

Additionally, if a vehicle fails a test, the vehicle must be taken offthe assembly line, repaired, and retested. To retest the vehicle, itmust be placed back on the assembly line and transported to theelectrical test segment of the line, which is time consuming. In otherwords, the throughput of the assembly plant is reduced each time avehicle requires retesting.

Moreover, it might happen that vehicles which have been tested and thenmoved out of the assembly building require modification or repair, inwhich case all of the affected vehicles must be moved back into thebuilding, onto the assembly line, and then retested at the electricaltest segment of the line. Such an event can severely reduce thethroughput of the assembly plant.

The present invention recognizes the above cost, space, and throughputdrawbacks of existing electrical test systems. Fortunately, the presentinvention further recognizes that it is possible to alleviate theseproblems using the inventive structures and methods disclosed herein.

In addition to the above considerations, the present inventionrecognizes that certain other advances can be made in vehicle electricaltesting. In particular, the present invention recognizes that it wouldbe advantageous to monitor the current flow from a vehicle's battery as,e.g., the electrically-powered window motors of the vehicle are beingtested, to determine whether a window is encountering mechanicalinterference with another vehicle component such as the door trimsurrounding the window. Still further, the present invention recognizesthat electrical test setpoints are currently hard-wired and consequentlycannot be easily changed by technicians at the assembly plant, and thatthis reduces the flexibility and maintainability of the test system.

And, prototypes of a vehicle's electrical system, colloquially referredto as "wiring bucks", cannot easily be tested using the same test systemthat is used to test manufactured vehicles on an assembly line. This isunfortunate, because deficiencies in a vehicle model's electrical systemmight be discovered more easily, and the test protocol for a model bevalidated more efficiently, if the wiring buck of a vehicle model couldbe tested using the same test system that is to be used on productionvehicles.

Accordingly, it is an object of the present invention to provide anelectrical test system for vehicle manufacturing quality assurance.

Another object of the present invention is to provide an electrical testsystem for vehicle manufacturing quality assurance that uses portablecomponents.

Still another object of the present invention is to provide anelectrical test system for vehicle manufacturing quality assurance thatcan be used anywhere in a vehicle assembly plant.

Yet another object of the present invention is to provide an electricaltest system for vehicle manufacturing quality assurance that measuresthe electric current flow of a vehicle battery during electricaltesting, to provide a further diagnostic indicator of the vehicle'selectrical system.

Another object of the present invention is to provide an electrical testsystem for vehicle manufacturing quality assurance that can be used on awiring buck.

Yet another object of the present invention is to provide an electricaltest system for vehicle manufacturing quality assurance that permitstest setpoints to be changed using software at an assembly plant.

Still another object of the present invention is to provide anelectrical test system for vehicle manufacturing quality assurance thatis easy to use and cost-effective.

SUMMARY OF THE INVENTION

A method for establishing test setpoints for electrical testing of avehicle during assembly includes, at a system computer, establishingsoftware-implemented test setpoints of a vehicle test protocol using aninput device. Then, the method includes entering, into a tester, avehicle identification number (VIN) that is associated with a vehiclehaving an electrical system. The VIN is transmitted via radiofrequency(RF) from the tester to the system computer, and at the system computer,the VIN is correlated to salescode information pertaining to theelectrical system of the vehicle. Next, the method includes transmittingthe salescode information to the tester via RF, and then executing thetest protocol in accordance with the salescode information to generatetest results in accordance with the test setpoints.

In a preferred embodiment, the salescode data is correlated at thetester to a test protocol, and the test protocol is transferred to atranslator engageable with a test receptacle of the vehicle. The testprotocol is executed to generate test results, with the test resultsthen transferred to the system computer. Preferably, the transferringsteps are accomplished by RF transmission. Indeed, test data istransmitted via RF from the translator to the tester.

Additionally, the preferred method includes transmitting the salescodedata only when the tester has transmitted a predetermined operatoridentification to the system computer, and executing the test protocolonly when the vehicle to be tested receives a predetermined electronickey. Per the preferred embodiment, the test protocol is aborted when apredetermined critical test has failed.

In another aspect, a method is disclosed for establishing test setpointsfor vehicle electrical testing during assembly. The method includesimplementing test setpoints for a test protocol using software in asystem computer, such that the setpoints can be changed by an operatorof the system computer. Also, the method includes generating a query ata portable tester adjacent the vehicle, and transferring the query tothe system computer. In response to the query, information that pertainsto the vehicle is transferred to the tester, and the setpoints also aretransferred to the tester. Then, the information is correlated to a testprotocol at the tester, with the test protocol being executed togenerate test results in accordance with the test setpoints.

In still another aspect, a computer program product is disclosed whichtangibly embodies a series of computer-executable instructions on one ormore data storage devices in computer usable form. The storage devicesinclude computer readable code means for receiving, from an inputdevice, vehicle electrical test setpoints, and computer readable codemeans for associating the test setpoints with a vehicle test protocol.

The details of the present invention, both as to its structure andoperation, can best be understood in reference to the accompanyingdrawings, in which like reference numerals refer to like parts, and inwhich:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the electrical test system, showingportions of the communication system and computer system schematically;

FIG. 2 is a block diagram of the hand held tester;

FIG. 3 is a block diagram of the translator;

FIG. 4 is a block diagram of the current monitor;

FIG. 5 is a flow chart of the overall method steps for testing a vehiclewiring buck and a vehicle; and

FIG. 6 is a flow chart showing details of computer-implemented portionsof the testing method of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1, a vehicle electrical test system isshown, generally designated 10, which includes one or more portable,hand-holdable testers 12 and one or more portable, hand-holdabletranslators 14 (only one tester 12 and one translator 14 shown in FIG. 1for clarity). As shown, the tester 12 includes a hollow, rigid,lightweight plastic or metal tester housing 16. As more fully disclosedbelow, a microprocessor (not shown in FIG. 1) is supported in the testerhousing 16, and the microprocessor presents data on a flat panel display18. Data can be input to the microprocessor by means of a keypad orkeyboard 20.

Additionally, bar-coded data can be entered into the microprocessor thatis within the tester housing 16 by scanning the data into a bar codereader 22, on the tester housing 16. A direct current, preferablerechargeable secondary battery 24 is also mounted on the tester housing16 and is electrically connected to the electrical components inside thehousing 16 as more fully described below. Furthermore, a radiofrequency(RF) tester antenna 26 is mounted on the housing 16 for purposes to beshortly disclosed. In the presently preferred embodiment, the tester 12is a microprocessor based device marketed under the trade name Telxon byDynetics, Inc. of Huntsville, Ala.

FIG. 1 shows that the tester 12 includes a data plug 28 and twoengagement receptacles 30. The translator 14 includes a lightweighthollow rigid plastic or metal translator housing 34, and a dataconnector 36 and two engagement posts 38 protrude outwardly therefromfor closely engaging the data plug 28 and engagement receptacles 30 ofthe tester 12 in respective interference fits. In this way, thetranslator 14 can be easily engaged with the tester 12 by pushing theposts 38 into the receptacles 30, and then easily disengaged from thetester 12 by pulling the translator 14 away from the tester 12, withoutthe need for tools. Further, when the translator 14 is engaged with thetester 12, data and power can be exchanged between the two via the dataconnector 36 and data plug 28. Alternatively, the translator 14 includesa direct current battery and a translator antenna 40, and data isexchanged between the tester 12 and translator 14 via the tester andtranslator antennae 26, 40, as described in detail below.

A cable 42 is connected to electrical components inside the translatorhousing 34, and the cable 42 terminates in a test plug 44. As shown, thetest plug 44 is configured for engaging a test receptacle 46 in avehicle 48 having an electrical system that is to be tested. It is to beunderstood that the test receptacle is in electrical communication withthe electrical system of the vehicle 48.

In addition to communicating with the translator 14 and, hence, with theelectrical system of the vehicle 48, the tester 12 can communicate viaRF with an associated current monitor 50 for monitoring the dischargecurrent of the battery 52 of the vehicle 48 during testing. In theembodiment shown, the current monitor 50 includes a hollow rigidlightweight plastic or metal monitor housing 54, and positive andnegative leads 56, 58 extend outwardly from the monitor housing 54. Asmore fully disclosed below, the leads 56, 58 are electrically connectedto current sensing components in the monitor housing 54. Also, each lead56, 58 terminates in a respective metal battery post clip 60, 62. Theclips 60, 62 are configured for engaging the positive and negativeterminals, respectively, of the battery 52. In one preferred embodiment,the clips 60, 62 are conventional jumper cable clips.

To facilitate communication between the tester 12 and the currentmonitor 52, a monitor antenna 64 protrudes from the monitor housing 54.As more fully disclosed below, the monitor antenna 64 is electricallyconnected to RF transceiving components within the monitor housing 54.

In accordance with the present invention, a system computer 66 is inwireless communication with the tester 12 for receiving communications,including queries in the form of vehicle identification numbers (VIN),and for transmitting vehicle salescode data to the tester 12 in responseto receiving the VIN. This salescode data contains information regardingthe specific electrical components in a particular vehicle, asidentified by the VIN of the vehicle. In response to receiving thesalescode data, the tester 12 generates test protocols which aretranslated into vehicle bus format by the translator 14. It is to beunderstood that the system computer 66 is a personal computer,mini-computer, or mainframe computer.

To facilitate the above-mentioned wireless communication, a wireless,preferably radiofrequency (RF) communication system is provided in avehicle assembly plant, generally designated 68, at which the vehicle 48to be tested is assembled. The preferred communication system has a datathroughput of at least two million bytes per second (2 mBps).

The plant 68 includes structural surfaces 70, such as walls, ceiling,girders, and the like, both load bearing and non-load bearing, andplural RF repeater transceivers 72 are mounted on the surfaces 70. FIG.1 shows one repeater transceiver 72 in phantom and one in solid,indicating that the repeater transceivers 72 can be mounted on interiorsurfaces of the plant 68 and on exterior surfaces of the plant 68 tofacilitate communication with a tester 12 substantially everywhere thetester 12 (and vehicle 48) is located inside the plant 68 or in anoutdoor parking area immediately adjacent the plant 68.

Accordingly, the skilled artisan will appreciate that the tester 12 cancommunicate with the repeater transceivers 72. In turn, the repeatertransceivers 72 communicate via RF with one or more central transceivers74. When the tester 12 is close to the central transceivers 74, thetester 12 can communicate directly with the central transceivers 74. Inany case, signals received by the central transceivers 74 are sent viaan optical fiber eight million bytes per second (8 mBps) ethernet 76 toconventional amplifying and digitizing circuitry 78, and thence to thesystem computer 66. Those skilled in the art will appreciate that thecircuitry 78 includes digital to analog converters (DAC) for convertingsignals from the computer 66 to analog format. Also, the circuitry 78includes analog to digital converters (ADC) for converting signals fromthe central transceivers 74 to digital format. In one preferredembodiment, the RF transceiver system described above is made by AeronetCorp. of Akron, Ohio, and the system operates at between than onegigaHertz and five gigaHertz (1 gHz-5 gHz), and preferably at two andfour tenths gigaHertz (2.4 gHz).

FIG. 1 schematically illustrates that the system computer 66 in theplant 68 can access a local database 80 that contains salescode and VINdata, using a local area network (LAN) 82. Moreover, the system computer66 can access, via a wide area network 86, a remote database 84 alsocontaining VIN and salescode data. Data can be input to the systemcomputer 66 by means of an appropriate input device 88, such as acomputer keyboard, keypad, mouse, trackball, touchscreen, or voiceactivated device.

A software-implemented test module 90 is accessible by the systemcomputer 66. It is to be understood that the tester microprocessordisclosed below accesses a complementary test module (not shown in FIG.1). Portions of FIGS. 5 and 6 show the logic of the test module 90. Itis to be understood that the test modules of the present invention areimplemented on device media. In one embodiment, the operations of thepresent test modules described below in reference to FIGS. 5 and 6 areembodied in a device medium such as software, i.e., in machine-readableform and stored on a computer program storage device. In other words,portions of FIGS. 5 and 6 illustrate the structures of the test modulesof the present invention as might be embodied in computer programsoftware or in logic circuits. Those skilled in the art will appreciatethat portions of FIGS. 5 and 6 illustrate the structures of computerprogram code elements that function according to this invention.Manifestly, the invention is practiced in its essential embodiment by amachine component that renders the computer program code elements in aform that instructs a digital processing apparatus (that is, a computer)to perform a sequence of function steps corresponding to those shown inthe Figures.

When embodied in software, these instructions may reside on a programstorage device including a data storage medium, such as can be found ona computer floppy diskette, on semiconductor devices, on magnetic tape,on optical disks, on a DASD array, on magnetic tape, on a conventionalhard disk drive, on electronic read-only memory or on electronic randomaccess memory, or other appropriate data storage device. In anillustrative embodiment of the invention, the computer-executableinstructions may be lines of compiled C language code and C⁺⁺ languagecode. In any case, apart from the particular computer program storagedevice (i.e., firmware logic circuits or software) that embodies thetest modules, as intended by the present invention, the test modules,including the test module 90 shown in FIG. 1, establish program meanswhich embody logic means that are recognizable by the system computer 66and tester microprocessor to perform the method steps disclosed below.

Now referring to FIG. 2, the tester 12 includes a microprocessor 92. Themicroprocessor 92 can be a 486 or Pentium® microprocessor or othersuitable computing device. As shown, the microprocessor 92 receives datafrom the bar code reader 22 and the keyboard 20.

Also, the microprocessor 92 accesses a test protocol database 94, which,like the other components of the tester 12, is contained in the testerhousing 16 (FIG. 1). In accordance with present principles, themicroprocessor 92 with test protocol database 94 includes data andBoolean logic circuits for generating test protocols for vehicles, basedon salescode data that is received by the microprocessor 92 from thesystem computer 66. In other words, based on the type of equipment thata particular vehicle has, as indicated by the salescode data, themicroprocessor 92 determines what tests must be executed on the vehicle,to assure electrical system quality. This correlating of salescode datato test protocols is undertaken in accordance with Boolean means knownin the art.

FIG. 2 also shows that the microprocessor 92 is electrically connectedto an RF tester transceiver 96 and thence to the tester antenna 26. Thetester transceiver 96 is an RF transceiver that includes amodulator/demodulator (for modulating and demodulating transmitted andreceived signals, respectively) and a mixer/oscillator.

When signals are received by the tester 12, they are sent from thetester transceiver 96 to an analog to digital converter (ADC) 98, andthen to the microprocessor 92. On the other hand, when signals from themicroprocessor 92 are to be transmitted, they are processed by a digitalto analog converter (DAC) 100, and then sent to the tester transceiver96 for transmission.

Now referring to FIG. 3, the electrical components within the translatorhousing 34 can be seen. As shown, the translator 14 includes acommunicator, such as an RF translator transceiver 102, that iselectrically connected to the translator antenna 40. Also, thetranslator transceiver 102 is electrically connected to a translatorunit 104, and the translator unit 104 in turn can be electricallyconnected via the test plug 44 and test receptacle 46 to a communicationbus 106 of the electrical system of the vehicle 48 (FIG. 1).

Per the present invention, the translator unit 104 translates databetween the tester microprocessor 92 communication protocol and the bus106 protocol. Thus, test protocol queries from the microprocessor 92 aretranslated into vehicle bus 106 format by the translator unit 104, tocause the electronic components of the vehicle to respond appropriately,i.e., to respond as commanded by the test protocol. These responses aretranslated back to microprocessor 92 format by the translator unit 104and compared by the microprocessor 92 to test setpoints, to determinewhether the vehicle 48 has passed the test.

In one embodiment, the translator unit 104 is implemented by electricalcircuitry that translates RS-232 formatted data (i.e., serialized datain a computer protocol form) into J1850 vehicle bus formatted data(i.e., data in a protocol form that can be understood by circuitry inthe vehicle 48), and vice-versa, in accordance with principleswell-known in the art. It is to be understood that the translator unit104 can be configured for cooperating with vehicle bus formats otherthan J1850, as appropriate for the particular vehicle model beingtested. It is to be further understood that appropriate ADC and DAC canbe used as appropriate.

In addition to the above-described translating function, the translator14 includes a voltage monitor or sensor 108 that is electricallyconnected to the test plug 44 and translator transceiver 102 as shown.The voltage monitor or sensor 108 generates a signal representative ofthe voltage on the bus 106, and this signal is transmitted to themicroprocessor 92 in the tester 12. The voltage can be used to monitorwhether satisfactory communication and testing has been accomplished onthe vehicle 48. In other words, the value of the voltage of the bus 106,as indicated by the voltage monitor or sensor 108 and transmitted to thetester 12 by the translator transceiver 102, indicates whethersatisfactory communication is being conducted between the bus 106 andthe translator 14.

Now referring to FIG. 4, the internal electronics of the current monitor50 can be seen. As shown, the current monitor 50 includes an RF monitortransceiver 110 that is electrically connected to the monitor antenna64. A current sensor 112 with associated electronics is electricallyconnected to the monitor transceiver 110, and the current sensor 112 isconnected via the leads 56, 58 to the vehicle battery 52. As intended bythe present invention, the current sensor 112 can be a Hall effectsensor or other suitable current sensing device for outputting a signalrepresentative of the current being drawn from the battery 52 duringtesting. This signal is transmitted to the tester 12 as mentionedpreviously, so that the microprocessor 92 can determine whetherexcessive current is being drawn from the battery 52 when, e.g.,electric windows of the vehicle 48 are being cycled during testing.

FIG. 5 shows the overall process flow of the present invention, usingthe structure described above. Commencing at block 114, the VIN of avehicle to be tested, e.g., the vehicle 48, is scanned into themicroprocessor 92 by passing the bar code reader 22 physically close tothe bar-coded VIN, as it is displayed on the vehicle 48. Or, the VIN canbe manually input into the microprocessor 92 by means of the keyboard20.

Next, at block 116, the microprocessor 92 of the tester 12 causes thetester transceiver 96 to transmit the VIN via the repeater transceivers72 and central transceivers 74 to the system computer 66. In response,the system computer 66 access the databases 80, 84 as appropriate toretrieve salescode data for the vehicle 48, based on the VIN. Thissalescode data is transmitted from the system computer 66 back to thetester 12 via the above-described RF system at block 118.

Moving to block 120, the salescode data is correlated to a test protocolby the microprocessor 92 of the tester 12, as described above. Next, atblock 122 a technician engages the test plug 44 of the translator 14with the test receptacle 46 of the vehicle 48.

It is to be understood that owing to the portability of the tester 12and translator 14, instead of engaging the test plug 44 with a testreceptacle of a vehicle, the test plug 44 can be engaged with a testreceptacle of a prototype version of a vehicle electrical system. Such aprototype is commonly referred to as a "wiring buck". Stateddifferently, the present invention advantageously affords theopportunity to execute the same diagnostic tests on a prototype versionof a vehicle electrical system as will be executed on productionversions of the vehicle in an assembly plant. In this way, systemicerrors in a vehicle model electrical system can be identified andcorrected relatively easily, before the system is implemented inproduction vehicles. Thus, the present steps can be conducted both onproduction vehicles in assembly plants, and on wiring bucks. Forsuccinctness, however, the remaining discussion will focus on productionvehicles, and more particularly the vehicle 48 shown in FIG. 1.

After engaging the translator 14 with the vehicle 48, at block 124 thetest protocol generated by the microprocessor 12 is executed bytransmitting the test protocol from the tester 12 to the translator 14,translating it to vehicle bus 106 format, and causing the vehicle 48 toundertake the tests. As indicated in FIG. 5, the vehicle 48 permits testexecution preferably only when an electronic "handshake" between thetranslator 14 and vehicle 48 is successful, i.e., only when thetranslator 14 first transmits an electronic key to unlock the vehiclebus 106. With this cooperation of structure, unauthorized post-assemblytesting is prevented.

Recall that the translator 14 monitors the voltage of the vehicle bus106 during testing and transmits a signal representative of this voltageto the tester 12. Proceeding to decision diamond 126, the microprocessor92 of the tester 12 determines whether the voltage of the vehicle bus106 as indicated by the translator 14 is satisfactory. If it is not, acommunication error is indicated, and the microprocessor 92 accordinglyreturns "communication error" at block 128. Then, the microprocessor 92logic moves to block 130 to transmit this determination to the systemcomputer 66.

If, on the other hand, it is determined at decision diamond 126 that thevoltage of the vehicle bus 106 is satisfactory, indicating satisfactorycommunication between the translator 14 and the bus 106, themicroprocessor 92 logic proceeds to decision diamond 132, to determinewhether the current being drawn from the battery 52 of the vehicle 48 issatisfactory, as indicated by the signal transmitted to the tester 12 bythe current monitor 50. If the battery current is not satisfactory, themicroprocessor 92 of the tester 12 moves to block 134 to return "batterycurrent unsatisfactory", and thence to block 130.

Otherwise, the logic of the microprocessor 92 proceeds to decisiondiamond 136 to determine whether all test results, as transmitted to thetester 12 from the translator 14, are satisfactory. If any tests havefailed, the microprocessor 92 logic proceeds to block 138 to return thenumbers or other designations of the tests that have failed. Incontrast, if no tests have failed, a message indicating "no failures" isreturned at block 140. From block 138 or block 140, the process moves toblock 130 to transmit the returned results to the system computer 66.

At block 142, the system computer 142 logs the test results by VIN andoutputs the results. The output can be hard copy, computer readablefile, video display, or other suitable form. The next vehicle to betested is accessed at block 144, with the process then returning toblock 114 to undertake testing on the next vehicle.

FIG. 6 shows details of the software that is executed by themicroprocessor 92 of the tester 12 and/or the system computer 66 in theassembly plant 68. Commencing at block 146, an operator of the systemcomputer 66, using an input device such as a mouse or keyboard, definesand/or modifies setpoints for responses to the various tests in a testprotocol. For example, the setpoints for time for window cycle in anelectric window test can be established at block 146. And, voltage andcurrent setpoints for various responses can be established at block 146.

In any case, the test protocol setpoints of the present invention can beeasily established or changed on site as necessary by modifying thesoftware-implemented setpoints using the input device 88, in contrast toexisting electrical test equipment in which test setpoints are hardwired into the test equipment. After establishing test setpoints, ifany, the new setpoints are transmitted to the testers of the presentinvention, e.g., to the tester 12 shown in FIG. 1. In response, thetesters update their local test protocol databases, e.g., the testprotocol database 94 shown in FIG. 2, as appropriate to reflect the newsetpoints.

Proceeding to block 148, an operator of the tester 12 initializes thetester 12 by defining whether certain features are enabled. For example,at block 148 an operator can define whether an "operator ID" variable isenabled, and whether an "abort test on failure of critical test" isenabled. Also, the operator can define whether an immediate retest uponfailure of a test is to be enabled.

Additionally, the present invention contemplates that in the event thata tester 12 unsuccessfully attempts to transmit data to the systemcomputer 66, the tester 12 will attempt, at intervals defined at block148, to retransmit the data. Furthermore, the operator may specify theperiodicities at which old data is deleted from the tester 12, and theperiod of storage for data which has not been transmitted to the systemcomputer 66. Moreover, the operator can specify the content of thereports sent by the tester 12 to the system computer 66, e.g., reportonly failures, report all results, etc.

After initialization of the tester 12, the process continues to block150, at which the VIN is input to the tester 12 as described above.Moving to decision diamond 152, the microprocessor 92 of the tester 12determines whether a variable "Get₋₋ Operator₋₋ ID" has been enabled atblock 148. If so, the tester 12 presents a prompt on the display 18 forthe operators identification. At decision diamond 156 it is determinedwhether the operator input a valid identification in response to theprompt, and if not, the process ends at error state 158. Otherwise, ifthe operator identification is valid, or, from decision diamond 152 isthe test there was negative, the process moves to block 160 to presenton the display 18 the VIN of the vehicle under test, a track sequencenumber, model type, and, after receiving the salescode data from thesystem computer 66 as described above, the salescode data of the vehicleunder test.

At block 162, the system computer 66 can transmit special testinstructions to the tester 12, if desired. For example, the systemcomputer 66 can instruct the tester 12 to execute only those tests thatthe particular vehicle might have previously failed. Or, the tester 12can be instructed to execute all tests, as for a previously untestedvehicle. In any case, as the test protocol is executed via thetranslator 14, the test status is updated on the display 18.

During the testing, the microprocessor 92 can move to decision diamond164 to determine whether a test that has been predesignated as"critical" has failed. If no critical test has failed, the process movesto block 166 to transmit the test results to the system computer 66. Onthe other hand, if the microprocessor 92 determines at decision diamond164 that a critical test has failed, the logic of the microprocessor 92moves to decision diamond 168 to determine whether a variable "Abort₋₋Test" has been enabled.

If the variable "Abort₋₋ Test" has not been enabled, indicating thattesting should continue despite the failure of a critical test, theprocess continues executing the test protocol and the results arereported at block 166. If, however, "Abort₋₋ Test" has been enabled, thelogic moves to block 170 to abort the test, and thence to block 166.

FIG. 6 shows that after the test results have been transmitted by thetester 12 to the system computer 66 at block 166, the logic moves todecision diamond 172 to determine whether the test results weresuccessfully transmitted, as might be indicated by, e.g., a checksumacknowledgement from the system computer 66. If the transmission wasunsuccessful, according to the determination at decision diamond 172,the tester 12 saves the untransmitted data at block 174, andretransmissions are attempted at the periodicity define at block 148.

From block 174, or from decision diamond 172 if it was determined thatthe data was successfully transmitted to the system computer 66, theprocess moves to decision diamond 176 to determine whether the vehiclefailed any tests in the test protocol. If not, the logic returns toblock 150 to test the next vehicle.

If, however, it is determined at decision diamond 176 that the vehicleunder test failed one or more tests in the protocol, the logic moves todecision diamond 178 to determine whether the operator enabled automaticexecution of retests at block 148. If so, the logic immediately executesa retest of the failed tests at block 180. From block 180, or fromdecision diamond 178 of the results of the decision were negative, thelogic returns to block 150 to await the next VIN.

While the particular ELECTRICAL TEST SYSTEM FOR VEHICLE MANUFACTURINGQUALITY ASSURANCE as herein disclosed and described in detail is fullycapable of attaining the above-described objects of the invention, it isto be understood that it is the presently preferred embodiment of thepresent invention and is thus representative of the subject matter whichis broadly contemplated by the present invention, that the scope of thepresent invention fully encompasses other embodiments which may becomeobvious to those skilled in the art, and that the scope of the presentinvention is accordingly to be limited by nothing other than theappended claims.

We claim:
 1. A method for establishing test setpoints for electricaltesting of a vehicle during assembly, comprising the steps of:at asystem computer, establishing software-implemented test setpoints of avehicle test protocol using an input device:entering into a tester avehicle identification number (VIN) associated with a vehicle having anelectrical system; transmitting the VIN via radiofrequency (RF) from thetester to the system computer; at the system computer, correlating theVIN to salescode information pertaining to the electrical system of thevehicle; transmitting the salescode information to the tester via RF;correlating the salescode data at the tester to testprotocol:transferring the test protocol to a translator engageable witha test receptacle of the vehicle; executing the test Protocol togenerate test results; executing the test protocol in accordance withthe salescode information to generate test results in accordance withthe test setpoints and; transferring the test results to the systemcomputer.
 2. The method of claim 1, where the transferring steps areaccomplished by RF transmission.
 3. The method of claim 2, furthercomprising the step of transmitting, via RF, test data from thetranslator to the tester.
 4. A method for establishing test setpointsfor vehicle electrical testing during assembly, comprising the stepsof:implementing test setpoints for a test protocol using software in asystem computer, such that the setpoints can be changed by an operatorof the system computer; generating a VIN at a portable tester adjacentthe vehicle; transferring the VIN to the system computer; in response tothe VIN, transferring salescode information pertaining to the vehicle tothe tester, and transferring the setpoints to the tester; correlatingthe information to a test protocol at the tester; transferring the testprotocol to a translator engageable with a test receptacle of thevehicle to execute the test protocol; executing the test protocol togenerate test results in accordance with the test setpoints, andtransferring the test results to the system computer, the transferringsteps being accomplished by RF transmission.
 5. A computer programproduct tangibly embodying a series of computer-executable instructionson one or more data storage devices in computer usable form, the storagedevices including:computer readable code means for receiving, from aninput device, vehicle electrical test setpoints; computer readable codemeans for associating the test setpoints with a vehicle test protocol;computer readable code means for generating a query at a portable testeradjacent a vehicle to be tested, the query based on the VIN of thevehicle; computer readable code means for transmitting the query via RFto a system computer; computer readable code means for, in response tothe query, transmitting salescode information pertaining to the vehicleto the tester via RF; computer readable code means for correlating theinformation to a test protocol at the tester; computer readable codemeans for transferring the test protocol to a translator engaqeable witha test receptacle of the vehicle to execute the test protocol; computerreadable code means for executing the test protocol to generate testresults in accordance with the setpoints; and computer readable codemeans for transferring the test results to the system computer.
 6. Thecomputer program product of claim 5, further comprising:computerreadable code means for generating a query at a portable tester adjacenta vehicle to be tested, the query being based on the VIN of the vehicle;computer readable code means for transmitting the query via RF to asystem computer; computer readable code means for, in response to thequery, transmitting salescode information pertaining to the vehicle tothe tester via RF; computer readable code means for correlating theinformation to a test protocol at the tester; computer readable codemeans for executing the test protocol to generate test results inaccordance with the setpoints; computer readable code means fortransferring the test protocol to a translator engageable with a testreceptacle of the vehicle to execute the test protocol; and computerreadable code means for transferring the test results to the systemcomputer.
 7. The computer program product of claim 5, further comprisingcomputer readable code means for transmitting, via RF, test data fromthe translator to the tester.
 8. The computer program product of claim7, further comprising:computer readable code means for transmitting thesalescode data only when the tester has transmitted a predeterminedoperator identification to the system computer; and computer readablecode means for executing the test protocol only when the vehicle to betested receives a predetermined electronic key.
 9. A method forestablishing test setpoints for electrical testing of vehicle duringassembly, comprising the steps of:at a system computer, establishingsoftware-implemented test setpoints of a vehicle test protocol using aninput device; entering into a tester a vehicle identification number(VIN) associated with a vehicle having an electrical system;transmitting the VIN via radio frequency (RF) from the tester to thesystem computer; at the system computer, correlating the VIN tosalescode information pertaining to the electrical system of thevehicle; transmitting the salescode information to the tester via RFonly when the tester has transmitted a predetermined operatoridentification to the system computer; correlating the salescode date atthe tester to a test protocol; transferring via RF the test protocol toa translator engageable with a test receptacle of the vehicle; executingthe test protocol in accordance with the salescode information only whenthe vehicle to be tested receives a predetermined electronic key togenerate test results in accordance with the test setpoints;transmitting via RF test data from the translator to the tester; andaborting the test protocol when a predetermined critical test hasfailed.
 10. A computer program product tangibly embodying a series ofcomputer-executable instructions on one or more data storage devices incomputer usable form, the storage devices including:computer readablecode means for receiving, from an input device, vehicle electrical testsetpoints; computer readable code means for associating the testsetpoints with a vehicle test protocol; computer readable code means forgenerating a query at a portable tester adjacent a vehicle to be tested,the query being based on the vehicle identification number of thevehicle; computer readable code means for transmitting via radiofrequency (RF), only when the tester has transmitted a predeterminedoperator identification to a system computer, the query to the systemcomputer; computer readable code means for, in response to the query,transmitting via RF salescode information pertaining to the vehicle tothe tester; computer readable code means for correlating the informationto a test protocol at the tester; computer readable code means forexecuting, only when the vehicle to be tested receives a predeterminedelectronic key, the test protocol to generate test results in accordancewith the setpoints; computer readable code means for transferring thetest protocol to a translator engageable with a test receptacle of thevehicle to execute the test protocol; computer readable code means fortransmitting via RF test data from the translator to the tester;computer readable code means for aborting the test protocol when apredetermined critical test has failed; computer readable code means forsaving the test results at the tester whom the test results are nottransmitted to the system computer; and computer readable code means forautomatically re-executing a test when the test has failed.